Mars chews up our wheels and spits them out. Take NASA’s one-ton, car-size, nuclear-powered Mars Curiosity robot: After just a year of cautious 0.09-mile-per-hour (144 metres) roving, small rocks began ripping large holes in its tyres.

However, NASA engineers have reinvented the wheel into a form that may one day conquer Mars.

They have created a nearly invincible tyre made of woven-mesh metal that “remembers” its ideal shape and immediately springs back into form after taking a beating.

The design, highlighted in a recent feature by the space agency, is rooted at NASA Glenn Research Center in Cleveland, Ohio. Engineer Colin Creager and his colleagues initially built a woven-mesh wheel made out of spring steel.

It gripped soft sand well and supported a lot of weight, yet kept hitting a major snag.

“We always came across this one problem of where the tyres would… get dents in them,” Creager said in a NASA video.

Then Creager bumped into materials scientist Santo Padula, who suggested using a shape-memory alloy – a super-elastic metal that pops back into place after intense strain.

“Since then, we’ve been collaborating .. to come up with this new tyre that we think is really going to revolutionise planetary rover tyres and potentially even tyres for Earth, too,” Creager said.

The torture of driving in space

NASA has been developing space-grade tyres since the 1960s, starting with its moon-landing program.

Those efforts led to mesh wheels on the Lunar Roving Vehicles, which astronauts drove during the Apollo 15, 16, and 17 missions.

Stiff metal strips in and on the tyres helped keep the LRVs moving on soft moon dust, yet also stood up to the punishment of small rocks.

The space agency later set its sights on Mars, spurring development in off-planet wheels. Yet the list of requirements for roving the red planet is daunting:

All-terrain: Mars is covered in sand, gravel, and boulders yet also littered with jagged rocks.

Durable: Solar or nuclear energy can help missions last more than a decade on the red planet.

Able to survive wild temperature swings: Inflated rubber tyres wouldn’t last on a nearly airless world with temperatures that can shift from nearly -200 degrees to 70 degrees Fahrenheit (-130 to -57 Celsius) in some locations.

Spring steel can only withstand 0.3 percent of strain (the distance the atoms in the metal shift) before it gets dented and the metal crystals permanently rearrange.

The NiTi alloy in question, however, can suffer up to 10 percent strain – about 30 times better elasticity.

As a result, the new wheels boast some impressive stats: They can bear nearly 10 times the weight of Curiosity’s wheels, function between -202 and 194°F (-130 and 90°C), have better grip over rocks and sand, and can climb slopes about 23 percent steeper.

“We [can] actually deform this all the way down to the axle and have it return to shape, which we could never even contemplate in a conventional-metal system,” Padula said of the new spring tyre in another NASA video.

Phillip Abel, a mechanical systems expert at NASA Glenn, said the key to the tyre’s performance are the stretchy bonds of the crystal structure in shape-memory alloys.

“With super-elastic materials, what you’re doing is .. storing the energy of deformation in the [crystal structure]. All of the atoms are more or less where they were,” Abel told Business Insider about the crystal structure shifts.

“The alloy, at the temperatures we’re seeing, is always in its ‘return to my original shape’ mode. So after you deform it, it pops back to its original crystal structure.”

In the toughest test to date, the wheels aced 10 kilometres of driving – more than half the total mileage of Curiosity on Mars – on punishing simulated terrain.

“The rim was a little dinged up, but the spring mesh tyre was like brand-new,” Creager said, adding the caveat that the test did not occur at blistering Martian conditions.

“In theory, they should work, but NASA JPL is building a cryogenic test chamber to verify operation at cold temperatures,” he said.

The long road ahead

Future and heavier Mars rover missions are in the works, putting pressure on NASA to redevelop its tyres.

A rover that’s nearly identical to Curiosity yet heavier, called Mars 2020, is scheduled to launch in just a few years.

Curiosity wasn’t outfitted with the newer wheels, since they weren’t developed before its launch, and Creager said it’s probably too late to put them on NASA’s upcoming Mars 2020 rover. (It takes a gruelling number of tests to prove the viability of a wheel for use on a space mission.)

“You can buy nickel-titanium alloy off the shelf, but you can’t just use it on Mars. There’s a treatment process,” Creager said.

Even with years of work, he added, “there’s still a lot we need to understand.”

However, they could be ready to roll for the Mars-sample-return mission in 2024.

The wheel’s applications aren’t limited only to the red planet, though; Creager, Abel, and Padula are working with Goodyear to put them on Earth-based vehicles.

So far, one they attached to a Jeep hugged around rocks without inflicting any damage to the spring tyre.

“I could definitely see it being used for any application where you’re driving off-road, and the risk of a puncture and a flat is a big deal, like with a military vehicle,” Creager said.

“But I would love to see this technology branching off to passenger vehicles.”